Material for Dissipating Heat From and/or Reducing Heat Signature of Electronic Devices and Clothing

ABSTRACT

Systems, methods and articles having a heat-shielding or blocking, heat-dissipating and/or heat signature-reducing material layer or coating are disclosed. In one example, the heat-shielding or blocking, heat-dissipating and/or heat signature-reducing material completely covers the interior of a housing having a plurality of battery cells removably disposed therein. Other examples include a heat-shielding or blocking, heat-dissipating and/or heat signature-reducing material layer having anti-static, anti-radio frequency (RF), anti-electromagnetic interference (EMI), anti-tarnish, and/or anti-corrosion materials and properties that effectively protect battery-operated devices and/or the batteries that power them from damage or diminished operation.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is related to and claims priority from the following USpatent applications: this application is a continuation-in-part of U.S.application Ser. No. 14/516,127, filed Oct. 16, 2014, which isincorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The presently invention relates generally to systems and methods ofdissipating heat, shielding objects from external heat and/or managingheat signatures of objects, including a material for dissipating heatfrom and/or reducing the heat signature of electronic devices and/orclothing.

2. Description of the Prior Art

The military uses various types of portable electronic devices, such asportable battery-operated radios, which generate heat during operation,i.e., during normal operation, the devices may be heat-generatingdevices. In particular, a malfunctioning device can cause excessiveheating. A drawback of heat-generating devices is that the heat may betransferred to the person using or carrying the device, causinguncomfortableness or burns. Another drawback of heat-generating devicesis that the heat may be transferred to other devices, causing damage tothese devices. Further, in military applications, heat-generatingdevices may increase the heat signature of military personnel, makingthem more prone to detection by thermal imaging and therefore more proneto danger.

It is known in the prior art to provide heat dissipating material orinsulating material with heat-generating devices.

Representative prior art patent documents include the following:

US Publication No. 20110100425 for heat dissipation sheet for the backface of solar battery module, and solar battery module using the same byinventors Osamura et al., filed Nov. 1, 2010 and published May 5, 2011,is directed to a heat dissipation sheet for the back face of a solarbattery module includes a heat dissipation film, and an adhesivecompound layer laminated on one face side of the heat dissipation film.The heat dissipation film preferably has a fine bumpy shape on theentire surface of another face. The heat dissipation film preferablyincludes a substrate layer in which the adhesive compound layer islaminated on one face side, and a heat dissipation layer laminated onanother face side of the substrate layer. The heat dissipation layerpreferably includes fine particles, and a binder for the fine particles.

US Publication No. 20130263922 for back sheet for solar cells and methodfor preparing the same by inventors Jung et al., filed Dec. 28, 2011 andpublished Oct. 10, 2013, is directed to a back sheet for solar cellsincluding a substrate, a fluororesin layer existing on one side of thesubstrate and a heat-dissipating ink layer existing on the other side ofthe substrate. Provided also is a method for preparing the same. Theback sheet for solar cells may have an excellent heat dissipationproperty as well as a high durability. Further, the method for preparingthe same may allow a cost-efficient production of solar cells.

US Publication No. 20080223428 for all printed solar cell array byinventor Zeira, filed Dec. 7, 2005 and published Sep. 18, 2008, isdirected to a method for producing a photovoltaic novelty item.Conductive polymer solutions and semiconductive oxide dispersions areformulated into inks that are laid down on top of one another to producevoltage and current when exposed to light. In addition, these inks maybe printed on novelty items, such as magazine advertisements or greetingcards, connecting to printed light emitting graphics.

US Publication No. 20080223431 for foldable solar panel by inventor Chu,filed Mar. 15, 2007 and published Sep. 18, 2008, is directed to afoldable solar panel comprising multiple rigid cell assemblies, multiplefolding cell assemblies and multiple primary flexible seams. Eachfolding cell assembly has two symmetric folding cell assembly halves anda flexible secondary seam. The symmetric folding cell assembly halvesare adjacent to each other. The secondary flexible seam connectsadjacent symmetric folding cell assembly halves and allows them to foldinward onto each other. A primary flexible seam connects a rigid cellassembly to an adjacent folding cell assembly to form an absorbingsurface. The primary flexible seams and secondary flexible seamsfacilitate folding the foldable solar penal to a small volume tofacilitate transportation or storage, and effectively keep the absorbingsurface from being damaged.

US Publication No. 20090229655 for solar cell by inventor Lee, filedMar. 13, 2008 and published September 17, 2009, is directed to a solarcell. The solar cell defines a receiving room in where at least a cellunit is located. A transparent cover plate is placed over the cell unit.In addition, the transparent cover plate includes a base plate and astructured plate which are adhered to each other. Wherein, the baseplate is made from inflexible material and the structured plate is madefrom a photo resin. Moreover, there are pluralities of convex firstpatterns disposed on the incident surface of the structured plate.

SUMMARY OF THE INVENTION

The present invention provides systems, methods and articles having aheat-shielding or blocking, heat-dissipating and/or heatsignature-reducing material layer or coating for functionally protectingarticles, electronic devices, batteries disposed within a housing, andhuman skin in contact with heat-producing objects. The term “housing” asused throughout this application refers to an apparatus which holdscasing-enclosed batteries (i.e. one or more sealed individualbatteries). In one example, the heat-shielding or blocking,heat-dissipating and/or heat signature-reducing material completelycovers the interior of a housing having a plurality of battery cellsremovably disposed therein. Other examples include a heat-shielding orblocking, heat-dissipating and/or heat signature-reducing material layerhaving anti-static, anti-radio frequency (RF), anti-electromagneticinterference (EMI), anti-tarnish, and/or anti-corrosion materials andproperties that effectively protect battery-operated devices and/or thebatteries that power them from damage or diminished operation.

In one embodiment, a housing with sealed battery cells disposed thereinis coated or lined with a heat-shielding or blocking, heat-dissipatingand/or heat signature-reducing material. Preferably, the heat-shieldingor blocking, heat-dissipating and/or heat signature-reducing materialcompletely covers the interior of a housing having a plurality ofbattery cells removably disposed therein. Other examples include aheat-shielding or blocking, heat-dissipating and/or heatsignature-reducing material layer having anti-static, anti-radiofrequency (RF), anti-electromagnetic interference (EMI), anti-tarnish,and/or anti-corrosion materials and properties that effectively protectbattery-operated devices and/or the batteries that power them fromdamage or diminished operation.

In another embodiment, the present invention provides an article fordissipating heat including a heat-dissipating layer; and one or moresubstrates disposed in close relation to the heat-dissipating layer. Oneaspect of the present invention provides a heat-dissipating layerincluding one or more of a material selected from the group including ananti-static material, an anti-radio frequency material, ananti-electromagnetic interference material, an anti-corrosion material,or an anti-tarnish material. Another aspect of the present inventionprovides a heat-dissipating layer that includes a copper shieldingplastic or a copper impregnated polymer.

In one embodiment of systems, methods, and articles of the presentinvention, a heat-dissipating material layer is uniformly distributed asa coating and/or lining on the internal sides of a housing for batterycomponents for functionally shielding the batteries disposed in thehousing from external heat, dissipating heat produced by the batteriesdisposed in the housing and reducing the heat signature associatedtherewith.

These and other aspects of the present invention will become apparent tothose skilled in the art after a reading of the following description ofthe preferred embodiment when considered with the drawings, as theysupport the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a cross-sectional view of one embodiment ofstructures that include material for dissipating heat from and/orreducing heat signature of electronic devices and/or clothing.

FIG. 1B illustrates a cross-sectional view of another embodiment ofstructures that include material for dissipating heat from and/orreducing heat signature of electronic devices and/or clothing.

FIG. 1C illustrates a cross-sectional view of yet another embodiment ofstructures that include material for dissipating heat from and/orreducing heat signature of electronic devices and/or clothing.

FIG. 1D illustrates a cross-sectional view of yet another embodiment ofstructures that include material for dissipating heat from and/orreducing heat signature of electronic devices and/or clothing.

FIG. 2A is a view of a radio holder article held in a pouch.

FIG. 2B is a view of the radio holder article of FIG. 2A removed fromthe pouch.

FIG. 3 is a perspective view of an example of a flexible solar panel.

FIG. 4 is an exploded view of an example of a flexible solar panel.

FIG. 5 is a perspective view of an example of a portable battery pack.

FIG. 6 is another perspective view of an example of a portable batterypack.

FIG. 7 is yet another perspective view of an example of a portablebattery pack.

FIG. 8 is a perspective view of an example of a wearable pouch of aportable battery pack.

FIG. 9 is another perspective view of an example of a wearable pouch ofa portable battery pack.

FIG. 10 is yet another perspective view of an example of a wearablepouch of a portable battery pack.

FIG. 11 illustrates various other views of wearable pouch of a portablebattery pack.

FIG. 12A illustrates an exploded view of an example of a battery of aportable battery pack.

FIG. 12B illustrates an exploded view of an example of a battery of aportable battery pack into which the heat dissipating and/or heatsignature-reducing material is installed.

FIG. 13 is a perspective view of a battery of a portable battery pack.

FIG. 14 is another perspective view of a battery of a portable batterypack.

FIG. 15 illustrates an exploded view of an example of a battery intowhich the heat dissipating and/or heat signature-reducing material isinstalled.

FIG. 16 illustrates a view of an example of a battery base.

FIG. 17 illustrates another view of an example of a battery base.

FIG. 18A illustrates a top view perspective of the battery lid.

FIG. 18B illustrates a cross-section view of the battery lid.

FIG. 18C illustrates a side view perspective of the battery lid.

FIG. 18D illustrates another cross-section view of the battery lid.

FIG. 19A illustrates a top view perspective of the battery base.

FIG. 19B illustrates a cross-section view of the battery base.

FIG. 19C illustrates a detail view of a part of the cross-section viewof the battery base shown in FIG. 19B.

FIG. 19D illustrates a side view perspective of the battery base.

FIG. 19E illustrates another cross-section view of the battery base.

FIG. 19F illustrates another side view perspective of the battery base.

FIG. 20 illustrates a view of a BA-5590 female connector.

FIG. 21 illustrates a block diagram of a portable power case into whichthe heat dissipating and/or heat signature-reducing material isinstalled.

FIG. 22 illustrates a block diagram showing the inside of one embodimentof the portable power case.

FIG. 23 illustrates a block diagram of the connections to the printedcircuit board (PCB).

FIG. 24 illustrates a view of the exterior of one embodiment of theportable power case.

FIG. 25 illustrates a view of the portable power case showing the USBports.

FIG. 26 illustrates one example of the portable power case lined withmaterial resistant to heat.

FIG. 27A illustrates the access ports of the portable power case.

FIG. 27B illustrates a keyway of the access ports of the portable powercase.

FIG. 28 illustrates a block diagram of a portable power case in an ATVwith three passengers.

FIG. 29 illustrates a block diagram of a portable power case in an ATVwith four passengers.

FIG. 30 illustrates a block diagram of the battery protector.

DETAILED DESCRIPTION

The present invention provides systems, methods and articles having aheat-shielding or blocking, heat-dissipating and/or heatsignature-reducing material layer or coating that functions to protectelectronic devices, articles, and/or human skin in contact with them. Inone example, the heat-shielding or blocking, heat-dissipating and/orheat signature-reducing material completely covers the interior of ahousing having a plurality of battery cells removably disposed therein.Other examples include a heat-shielding or blocking, heat-dissipatingand/or heat signature-reducing material layer having anti-static,anti-radio frequency (RF), anti-electromagnetic interference (EMI),anti-tarnish, and/or anti-corrosion materials and properties thateffectively protect battery-operated devices and/or the batteries thatpower them from damage or diminished operation

In one embodiment of the present invention, the heat-dissipating layerincludes one or more of a material selected from the group consisting ofan anti-static material, an anti-radio frequency material, ananti-electromagnetic interference material, an anti-corrosion material,an anti-tarnish material, and combinations thereof. Preferably, the heatdissipating material layer or coating includes a copper shieldingplastic, and more preferably, the heat dissipating material layer orcoating includes a copper impregnated polymer.

In alternate embodiments, one substrate is bonded to theheat-dissipating layer; one substrate is loosely arranged in relation tothe heat-dissipating layer; a first substrate and a second substratewherein the heat-dissipating layer is sandwiched between the first andsecond substrate, or the first and second substrates are bonded to theheat-dissipating layer, or the first and second substrates are looselyarranged in relation to the heat-dissipating layer, or the firstsubstrate is bonded to the heat-dissipating layer and the secondsubstrate is loosely arranged in relation to the heat-dissipating layer.In these various embodiments, the one or more substrates are flexible,rigid, or a combination thereof; the one or more substrates include afabric; the one or more substrates comprise one or more of glass,plastic, or metal; or the one or more substrates comprise multi-layerstructures.

In one embodiment of the present invention, the article including aheat-dissipating material layer is configured to fit inside a hand-heldradio holder. In yet another embodiment, the article includes a solarpanel assembly sandwiched between a first substrate and theheat-dissipating layer.

In an exemplary embodiment, the heat shielding or blocking, orheat-dissipating material is used to prevent and/or minimize heattransfer and the heat signature produced from batteries, as well as toprevent and/or minimize heat transfer from external heat-producingarticles or objects. Team operations in remote locations, such asmilitary operations, require radios to allow team members to communicateabout danger, injuries, opportunities, etc. Without radios in theseenvironments, more people would be injured or die. However, most radiossuitable for these environments are high powered radios which typicallyrequire lithium ion batteries. While lithium ion batteries are capableof providing a lot of power, lithium ion batteries have produced a largeamount of heat since their inception. The heat produced from lithium ionbatteries is capable of causing radiation burns to radio operators, eventhrough layers of clothing. This heat also increases the heat signatureof soldiers, making them more vulnerable to enemy thermal imagingtechnology. In extreme cases, malfunctions in lithium ion batteriescause fires. Heat produced from lithium ion batteries is also capable ofdamage the radio itself or other electronic devices critical tosurvival.

Additionally, shipping lithium ion batteries or devices with lithium ionbatteries is banned or highly regulated in most parts of the world dueto the risk of overheating and/or fire. What is needed is a materialwhich can be incorporated within a battery housing for a with lithiumbatteries, but not on the batteries themselves, to prevent the risk ofoverheating and fire. As lithium ion batteries were developed in the1970s and have been in commercial use since the 1990s, there is along-felt unmet need for systems, methods, and apparatuses to reduce,eliminate, or contain the heat produced from batteries for saferoperation of radios and other electronic devices critical to survival.

None of the prior art provides a housing, base, container, or case forone or more batteries which dissipates the heat produced by the one ormore batteries during operation, thus reducing the heat signature of thehousing and preventing the housing from heating and causing discomfortand/or burns to an operator in contact with the housing.

Certain aspects of the presently disclosed subject matter of theinvention, having been stated hereinabove, are addressed in whole or inpart by the presently disclosed subject matter, and other aspects willbecome evident as the description proceeds when taken in connection withthe accompanying illustrative examples and figures as best describedherein below.

Referring now to the drawings in general, the illustrations are for thepurpose of describing a preferred embodiment of the invention and arenot intended to limit the invention thereto.

The present invention provides a material for 1) reducing or eliminatingheat exposure from external objects or other heat-producing devices; 2)dissipating heat from at least one battery or heat-producing electronicdevice; and/or 3) reducing the heat signature of electronic devicesand/or clothing. The heat blocking or shielding, heat-dissipating,and/or heat signature-reducing material is incorporated into the housingof a heat-producing device or battery pack housing, or any article ofclothing or fabric. In one example, a heat shielding or blocking,heat-dissipating, and/or heat signature-reducing material layer issandwiched between two substrates, wherein the substrates may beflexible, rigid, or a combination of both flexible and rigid.

When applied to clothing, the heat blocking or shielding,heat-dissipating, and/or heat signature-reducing material is operable toprotect a person's skin from burns from a heat-generating article orsource. Surprisingly, one embodiment of the heat blocking or shielding,heat-dissipating and/or heat signature-reducing material layer wasdiscovered when it was in a person's hand but they were not burned by aheat gun when holding the material in hand, between the heat gun andskin. It was later tested and proved completely heat-resistant,heat-shielding, and/or heat-dissipating up to temperatures of heat guns(up to about 1,000 degrees Fahrenheit), propane torches (up to about3,623 degrees Fahrenheit), and oxygen-fed torches (up to about 5,110degrees Fahrenheit). These surprising test results combined with othertrials generated the embodiments of the present invention and theparticular examples that are described herein, in particular for liningsor coatings that are constructed and configured especially for heatblocking or shielding, heat-dissipating and/or heat signature-reducingmaterial layer or coating applied to objects for protecting an articlefrom any external heat source, as well as dissipating heat produced byheat-producing devices and their batteries.

FIG. 1A and FIG. 1B are cross-sectional views of examples of structuresthat include the material for dissipating heat from and/or reducing heatsignature of electronic devices and/or clothing. The heat-dissipatingand/or heat signature-reducing material can be used in combination with,for example, one or two substrates. For example, FIG. 1A shows astructure 100 that includes a heat-dissipating and/or heatsignature-reducing layer 120. The heat-dissipating and/or heatsignature-reducing layer 120 can be sandwiched between a first substrate125 and a second substrate 130.

The heat-dissipating and/or heat signature-reducing layer 120 can be anymaterial that is suitable for dissipating heat from and/or reducing theheat signature of electronic devices and/or clothing. Theheat-dissipating and/or heat signature-reducing layer 120 can be fromabout 20 μm thick to about 350 μm thick in one example. In particularembodiments, the heat-dissipating and/or heat signature-reducing layer120 can have a thickness ranging from about 1 mil to about 6 mil,including, but not limited to, 1, 2, 3, 4, 5, and 6 mil, or about 25 μmto about 150 μm, including, but not limited to, 25, 50, 75, 100, 125,and 150 μm. Examples of the heat-dissipating and/or heatsignature-reducing layer 120 include anti-static, anti-radio frequency(RF), and/or anti-electromagnetic interference (EMI) materials, such ascopper shielding plastic or copper particles bonded in a polymer matrix,as well as anti-tarnish and anti-corrosion materials. A specific exampleof the heat-dissipating and/or heat signature-reducing layer 120 is theanti-corrosive material used in Corrosion Intercept Pouches, catalognumber 034-2024-10, available from University Products Inc. (Holyoke,Mass.). The anti-corrosive material is described in U.S. Pat. No.4,944,916 to Franey, which is incorporated by reference in its entirety.Such materials can comprise copper shielded or copper impregnatedpolymers including, but not limited to, polyethylene, low-densitypolyethylene, high-density polyethylene, polypropylene, and polystyrene.In another embodiment, the heat shielding or blocking, heat-dissipating,and/or heat signature-reducing layer is a polymer with aluminum and/orcopper particles incorporated therein. In particular, the surface areaof the polymer with aluminum and/or copper particles incorporatedtherein preferably includes a large percent by area of copper and/oraluminum. By way of example and not limitation, the surface area of theheat-dissipating and/or heat signature-reducing layer includes about 25%by area copper and/or aluminum, 50% by area copper and/or aluminum, 75%by area copper and/or aluminum, or 90% by area copper and/or aluminum.In one embodiment, the heat shielding or blocking, heat-dissipating,and/or heat signature-reducing layer is substantially smooth and notbumpy. In another embodiment, the heat shielding or blocking,heat-dissipating, and/or heat signature-reducing layer is not flat butincludes folds and/or bumps to increase the surface area of the layer.Alternatively, the heat-shielding or blocking, heat-dissipating and/orheat signature-reducing layer 120 includes a fabric having at least onemetal incorporated therein or thereon. The fabric further includes asynthetic component, such as by way of example and not limitation, anylon, a polyester, or an acetate component. Preferably, the at leastone metal is selected from the group consisting of copper, nickel,aluminum, gold, silver, tin, zinc, or tungsten.

The first substrate 125 and the second substrate 130 can be any flexibleor rigid substrate material. An example of a flexible substrate is anytype of fabric. Examples of rigid substrates include, but are notlimited to, glass, plastic, and metal. A rigid substrate may be, forexample, the housing of any device. In one example, both the firstsubstrate 125 and the second substrate 130 are flexible substrates. Inanother example, both the first substrate 125 and the second substrate130 are rigid substrates. In yet another example, the first substrate125 is a flexible substrate and the second substrate 130 is a rigidsubstrate. In still another example, the first substrate 125 is a rigidsubstrate and the second substrate 130 is a flexible substrate. Further,the first substrate 125 and the second substrate 130 can be single-layeror multi-layer structures.

In structure 100 of FIG. 1A, the heat-shielding or blocking,heat-dissipating and/or heat signature-reducing layer 120, the firstsubstrate 125, and the second substrate 130 are bonded or otherwiseattached together, by way of example and not limitation, by adhesive,stitching, hook-and-loop fastener system). In another example andreferring now to FIG. 1B, in a structure 105, the first substrate 125 isbonded to one side of the heat shielding or blocking, heat-dissipating,and/or heat signature-reducing layer 120, whereas the second substrate130 is not bonded or otherwise attached to the other side of the heatshielding or blocking, heat-dissipating, and/or heat signature-reducinglayer 120. In yet another example and referring now to FIG. 1C, in astructure 110, the first substrate 125 is provided loosely against oneside of the heat shielding or blocking, heat-dissipating, and/or heatsignature-reducing layer 120 and the second substrate 130 is providedloosely against the other side of the heat-dissipating and/or heatsignature-reducing layer 120. The first substrate 125 and the secondsubstrate 130 are not bonded or otherwise attached to the heat shieldingor blocking, heat-dissipating, and/or heat signature-reducing layer 120.In still another example and referring now to FIG. 1D, in a structure115, the heat shielding or blocking, heat-dissipating, and/or heatsignature-reducing layer 120 is provided in combination with the firstsubstrate 125 only, either bonded or loosely arranged. In FIG. 1D, ifthe two layers are loosely arranged, the heat-dissipating and/or heatsignature-reducing layer 120 is not bonded or otherwise attached to thefirst substrate 125. The presently disclosed material is not limited tothe structures 100, 105, 110, 115. These structures are exemplary only.

The heat-shielding or blocking, heat-dissipating and/or heatsignature-reducing layer 120 can be used as a protective shield againstheated objects and also for reducing the heat signature of objects. Forexample, in military applications, the heat shielding or blocking,heat-dissipating, and/or heat signature-reducing layer 120 can be usedto reduce the heat signature of devices or clothing for militarypersonnel to reduce the risk of their being detected by thermal imaging.

Other examples of applications and/or uses of the heat-shielding orblocking, heat-dissipating and/or heat signature-reducing layer 120include, but are not limited to, insulating battery packs, for examplein any battery housing or electronic device housing; protecting deviceand/or users from undesirable external heat; forming sandwichstructures; form fitting to a particular device; enclosing electronicmaterials to prevent corrosion or feathering; medical applications toprotect patients from heated devices used in surgical procedures, forexample, in robotics (e.g., for use in disposable, sterile drapes);forming solar panels; lining tents (e.g., to prevent heat from going inor out); forming heat shields or guards for mufflers on, for example,motorcycles, lawn mowers, leaf blowers, or weed eaters; lining gloves toprotect from flames, handling ice, and/or for preparing food (includingpastry preparation).

Other examples of protective flexible heat shielding applications inwhich the heat-dissipating and/or heat signature-reducing layer 120 canbe used include gloves (e.g., fire pit gloves, gloves/forearm shieldsfor operating two-stroke engine yard equipment), integrated in uniforms(e.g., nurses/scrub technicians in operating rooms vs. electro cautery),motorcyclist (clothing) protection from tail pipes, protective shieldingin radio pouches (e.g., protecting person from radio heat, protectingradio from heating battery, protecting battery from heating radio,protecting battery from external heat sources), protection on the bottomof a laptop (inside the laptop housing), protection layer from heat oflaptop for laps (e.g., lap tray) and expensive furniture (e.g.,furniture pad), and portable protective heat shield (e.g., protectsensitive electronics and persons, varies in sizes).

FIG. 2A is a perspective view of a radio holder article 200 into whichthe heat-shielding or blocking, heat-dissipating and/or heatsignature-reducing layer 120 is installed. The radio holder article 200is an example of equipment that may be used by military personnel. Theradio holder article 200 is but one example of using the heat-shieldingor blocking, heat-dissipating and/or heat signature-reducing layer 120for dissipating heat from and/or reducing the heat signature of anarticle. Military radios often get hot and can cause burns to the user.

The radio holder article 200 can be removably held in a pouch 210 andworn on a user's belt 230. FIG. 2B is a view of the radio holder article200 removed from the pouch 210. In this example, a structure, such asthe structure 115 of FIG. 1D, is formed separately and then insertedinto the pouch 210 of the radio holder article 200. In another example,in the case of the structure 105 of FIG. 1B, the radio holder article200 itself serves as the second substrate 130. This allows the radioholder article 200 to be easily removed from the pouch 210. It alsoprovides for retrofitting the pouch with heat protection from theheat-shielding or blocking, heat-dissipating and/or heatsignature-reducing material layer or coating.

Alternatively, the radio holder article 200 is permanently held in thepouch 210. The pouch 210 is formed using a structure, such as thestructure 100 of FIG. 1A. The pouch 210 includes a pouch attachmentladder system (PALS) adapted to attach the pouch to a load-bearingplatform (e.g., belt, rucksack, vest). In a preferred embodiment, thepouch 210 is MOLLE-compatible. “MOLLE” means Modular LightweightLoad-carrying Equipment, which is the current generation of load-bearingequipment and backpacks utilized by a number of NATO armed forces.

In this example, the heat-shielding or blocking, heat-dissipating and/orheat signature-reducing layer 120 protects the user from heat from theradio (not shown), the heat shielding or blocking, heat-dissipating,and/or heat signature-reducing layer 120 protects the radio (not shown)from any external heat source (e.g., a hot vehicle), and the heatshielding or blocking, heat-dissipating, and/or heat signature-reducinglayer 120 reduces the heat signature of the radio (not shown).

In a preferred embodiment, the substrate 225 can be formed of anyflexible, durable, and waterproof or at least water resistant material.For example, the substrate 225 can be comprised of polyester, polyvinylchloride (PVC)-coated polyester, vinyl-coated polyester, nylon, canvas,PVC-coated canvas, or polycotton canvas. The exterior finish of thesubstrate 225 can be any color, such as white, brown, or green, or anypattern, such as camouflage, as provided herein, or any other camouflagein use by the military.

Representative camouflages include, but are not limited to, universalcamouflage pattern (UCP), also known as ACUPAT or ARPAT or Army CombatUniform; MultiCam, also known as Operation Enduring Freedom CamouflagePattern (OCP); Universal Camouflage Patter-Delta (UCP-Delta); AirmanBattle Uniform (ABU); Navy Working Uniform (NWU), including variants,such as, blue-grey, desert (Type II), and woodland (Type III); MARPAT,also known as Marine Corps Combat Utility Uniform, including woodland,desert, and winter/snow variants; Disruptive Overwhite Snow digitalcamouflage, and Tactical Assault Camouflage (TACAM).

FIG. 3 and FIG. 4 are a perspective view and an exploded view,respectively, of a flexible solar panel article 300 into which theheat-shielding or blocking, heat-dissipating and/or heatsignature-reducing layer 120 is installed. The flexible solar panelarticle 300 is another example of equipment that may be used by militarypersonnel. The flexible solar panel article 300 is but another exampleof using the heat shielding or blocking, heat-dissipating and/or heatsignature-reducing layer 120 for shielding or blocking external heat to,and/or dissipating heat from and/or reducing the heat signature of anarticle.

In this example, the flexible solar panel article 300 is a flexiblesolar panel that can be folded up and carried in a backpack and thenunfolded and deployed as needed. The flexible solar panel article 300 isused, for example, to charge rechargeable batteries or to powerelectronic equipment directly.

The flexible solar panel article 300 is a multilayer structure thatincludes multiple solar modules 322 mounted on a flexible substrate,wherein the flexible substrate with the multiple solar modules 322 issandwiched between two layers of fabric. Windows are formed in at leastone of the two layers of fabric for exposing the solar modules 322.

A hem 324 may be provided around the perimeter of the flexible solarpanel article 300. In one example, the flexible solar panel article 300is about 36×36 inches. The output of any arrangement of solar modules322 in the flexible solar panel article 300 is a direct current (DC)voltage. Accordingly, the flexible solar panel article 300 includes anoutput connector 326 that is wired to the arrangement of solar modules322. The output connector 326 is used for connecting any type of DC loadto the flexible solar panel article 300. In one example, the flexiblesolar panel article 300 is used for supplying power a device, such as aDC-powered radio. In another example, the flexible solar panel article300 is used for charging a battery.

The flexible solar panel article 300 includes a solar panel assembly 328that is sandwiched between a first fabric layer 330 and a second fabriclayer 332. The first fabric layer 330 and the second fabric layer 332can be formed of any flexible, durable, and substantially waterproof orat least water resistant material, such as but not limited to,polyester, PVC-coated polyester, vinyl-coated polyester, nylon, canvas,PVC-coated canvas, and polycotton canvas. The first fabric layer 330 andthe second fabric layer 332 can be any color or pattern, such as thecamouflage pattern shown in FIG. 3 and FIG. 4.

The solar panel assembly 328 of the flexible solar panel article 300includes the multiple solar modules 322 mounted on a flexible substrate334. A set of windows or openings 340 is provided in the first fabriclayer 330 for exposing the faces of the solar modules 322. The flexiblesubstrate 334 is formed of a material that is lightweight, flexible(i.e., foldable or rollable), printable, and substantially waterproof orat least water resistant.

In the flexible solar panel article 300, the heat-dissipating and/orheat signature-reducing layer 120 is incorporated into the layers offabric that form the flexible solar panel article 300, in similarfashion to the structure 100 of FIG. 1A. Namely, the heat-dissipatingand/or heat signature-reducing layer 120 is provided at the back ofsolar modules 322, between the flexible substrate 334 and the secondfabric layer 332. In this example, the first fabric layer 330, theflexible substrate 334, the heat-dissipating and/or heatsignature-reducing layer 120, and the second fabric layer 332 are heldtogether by stitching and/or by a hook-and-loop fastener system.

In this example, the heat-shielding or blocking, heat-dissipating and/orheat signature-reducing layer 120 protects the user from heat from theback of the flexible solar panel article 300, the heat-shielding orblocking, heat-dissipating and/or heat signature-reducing layer 120protects the back of the flexible solar panel article 300 from anyexternal heat source (not shown), and the heat-dissipating and/or heatsignature-reducing layer 120 reduces the heat signature of the flexiblesolar panel article 300.

FIGS. 5-7 are perspective views of a portable battery pack 500 intowhich the heat dissipating and/or heat signature-reducing material isinstalled. The portable battery pack 500 is an example of equipment thatmay be used by military personnel. The portable battery pack 500 is butone example of using the heat-shielding or blocking, heat-dissipatingand/or heat signature-reducing layer 120 for dissipating heat fromand/or reducing the heat signature of an article. In a preferredembodiment, the portable battery pack comprises a portable battery packsuch as that disclosed in US Publication No. 20160118634, which isincorporated by reference in its entirety.

Portable battery pack 500 comprises a pouch 510 for holding a battery550. Pouch 510 is a wearable pouch or skin that can be sized in anymanner that substantially corresponds to a size of battery 550. In oneexample, pouch 510 is sized to hold a battery 550 that is about 9.75inches long, about 8.6 inches wide, and about 1 inch thick.

Pouch 510 is formed of any flexible, durable, and substantiallywaterproof or at least water resistant material. For example, pouch 510can be formed of polyester, polyvinyl chloride (PVC)-coated polyester,vinyl-coated polyester, nylon, canvas, PVC-coated canvas, or polycottoncanvas. The exterior finish of pouch 510 can be any color, such aswhite, brown, or green, or any pattern, such as camouflage, as providedherein, or any other camouflage in use by the military. For example, inFIG. 5, FIG. 6, and FIG. 7, pouch 510 is shown to have a camouflagepattern.

Representative camouflages include, but are not limited to, universalcamouflage pattern (UCP), also known as ACUPAT or ARPAT or Army CombatUniform; MultiCam, also known as Operation Enduring Freedom CamouflagePattern (OCP); Universal Camouflage Patter-Delta (UCP-Delta); AirmanBattle Uniform (ABU); Navy Working Uniform (NWU), including variants,such as, blue-grey, desert (Type II), and woodland (Type III); MARPAT,also known as Marine Corps Combat Utility Uniform, including woodland,desert, and winter/snow variants; Disruptive Overwhite Snow digitalcamouflage, and Tactical Assault Camouflage (TACAM).

Pouch 510 has a first side 512 and a second side 514. Pouch 510 alsocomprises an opening 516, which is the opening through which battery 550is fitted into pouch 510. In one example, opening 516 is opened andclosed using a zipper, as such pouch 510 includes a zipper tab 518.Other mechanisms, however, can be used for holding opening 516 of pouch510 open or closed, such as, a hook and loop system (e.g., Velcro®),buttons, snaps, hooks, and the like. Further, an opening 520 (see FIG.6, FIG. 7, FIG. 9) is provided on the end of pouch 510 that is oppositeopening 516. For example, opening 520 can be a 0.5-inch long slit or a0.75-inch long slit in the edge of pouch 510.

In one embodiment, the pouch is a multi-layer structure, such as thestructure 100 of FIG. 1A, including at least one layer of theheat-dissipating and/or heat signature-reducing layer. In thisembodiment, the heat-dissipating and/or heat signature-reducing layer ispermanently attached to the pouch. Alternatively, a structure, such asthe structure 115 of FIG. 1D, is formed separately and then insertedinto the pouch 510 of the portable battery pack 500. This allows theuser to retrofit an existing pouch with heat protection. The retrofitstructure comprises a structure, such as the structure 115 of FIG. 1D,for protecting the first side 512 and/or the second side 514. Theretrofit structure comprises a large structure that is operable to wraparound the battery 550 in an alternative embodiment.

In one example, battery 550 is a rechargeable battery that comprises twoleads 552 (e.g., leads 552 a, 552 b). Each lead 552 can be used for boththe charging function and the power supply function. In other words,leads 552 a, 552 b are not dedicated to the charging function only orthe power supply function only, both leads 552 a, 552 b can be used foreither function at any time. In one example, one lead 552 can be usedfor charging battery 550 while the other lead 552 can be usedsimultaneously for powering equipment, or both leads 552 can be used forpowering equipment, or both leads 552 can be used for charging battery550.

With respect to using battery 550 with pouch 510, first the user unzipsopening 516, then the user inserts one end of battery 550 that has, forexample, lead 552 b through opening 516 and into the compartment insidepouch 510. At the same time, the user guides the end of lead 552 bthrough opening 520, which allows the housing of battery 550 to fitentirely inside pouch 510, as shown in FIG. 5. Lead 552 a is leftprotruding out of the unzipped opening 516. Then the user zips opening516 closed, leaving zipper tab 518 snugged up against lead 552 a, asshown in FIG. 6 and FIG. 7. Namely, FIG. 6 shows portable battery pack500 with side 512 of pouch 510 up, whereas FIG. 7 shows portable batterypack 500 with side 514 of pouch 510 up.

Pouch 510 of portable battery pack 500 can be MOLLE-compatible. “MOLLE”means Modular Lightweight Load-carrying Equipment, which is the currentgeneration of load-bearing equipment and backpacks utilized by a numberof NATO armed forces. Namely, pouch 510 incorporates a pouch attachmentladder system (PALS), which is a grid of webbing used to attach smallerequipment onto load-bearing platforms, such as vests and backpacks. Forexample, the PALS grid consists of horizontal rows of 1-inch (2.5 cm)webbing, spaced about one inch apart, and reattached to the backing at1.5-inch (3.8 cm) intervals. Accordingly, a set of straps 522 (e.g.,four straps 522) are provided on one edge of pouch 510 as shown.Further, four rows of webbing 524 are provided on side 512 of pouch 510,as shown in FIG. 7. Additionally, four rows of slots or slits 526 areprovided on side 514 of pouch 510, as shown in FIG. 7.

FIGS. 8-10 are perspective views of an example of wearable pouch 510 ofthe portable battery pack 500. Namely, FIG. 8 shows details of side 512of pouch 510 and of the edge of pouch 510 that includes opening 516.FIG. 8 shows opening 516 in the zipper closed state. Again, four rows ofwebbing 524 are provided on side 512 of pouch 510. FIG. 9 also showsdetails of side 512 of pouch 510, but showing the edge of pouch 510 thatincludes opening 520. FIG. 10 shows details of side 514 of pouch 510 andshows the edge of pouch 510 that includes opening 516. FIG. 10 showsopening 516 in the zipped closed state. Again, four rows of slots orslits 526 are provided on side 514 of pouch 510.

FIG. 11 illustrates various other views of wearable pouch 510 of theportable battery pack 500. Namely, FIG. 11 shows a plan view A, which isside 512 of pouch 510; a plan view B, which is side 514 of pouch 510; aside view; an end view A, which is the non-strap end of pouch 510; andan end view B, which is the strap 512-end of pouch 510.

FIG. 12A is an exploded view of an example of battery 550 of theportable battery pack 500. Battery 550 includes a battery element 564that is housed between a battery cover 554 and a back plate 562. Batteryelement 564 supplies leads 552 a, 552 b. In one example, the output ofbattery element 564 can be from about 5 volts DC to about 90 volts DC atfrom about 0.25 amps to about 10 amps.

FIG. 12B illustrates an exploded view of an example of a battery 550 ofthe portable battery pack 500 into which the heat dissipating and/orheat signature-reducing material is installed. Battery 550 includes abattery element 564 that is housed between a battery cover 554 and aback plate 562. A first heat-dissipating and/or heat signature-reducinglayer 570 is between the battery cover 554 and the battery element 564.The first heat-dissipating and/or heat signature-reducing layer 570protects the battery from external heat sources (e.g., a hot vehicle). Asecond heat-dissipating and/or heat signature-reducing layer 572 isbetween the battery element 564 and the back plate 562. The secondheat-dissipating and/or heat signature-reducing layer 572 protects theuser from heat given off by the battery element 564.

Battery cover 554 comprises a substantially rectangular compartment 556that is sized to receive battery element 564. A top hat style rim 558 isprovided around the perimeter of compartment 556. Additionally, twochannels 560 (e.g., channels 560 a, 560 b) are formed in battery cover554 (one on each side) to accommodate the wires of leads 552 a, 552 bpassing therethrough.

Battery cover 554 and back plate 562 can be formed of plastic using, forexample, a thermoform process or an injection molding. Back plate 562can be mechanically attached to rim 558 of battery cover 554 via, forexample, an ultrasonic spot welding process or an adhesive.Additionally, a water barrier material, such as silicone, may be appliedto the mating surfaces of rim 558 and back plate 562. Battery cover 554,back plate 562, and battery element 564 can have a slight curvature orcontour for conforming to, for example, the user's vest, backpack, orbody armor.

FIG. 13 and FIG. 14 are perspective views of battery 550 of the portablebattery pack 500 when fully assembled. Namely, FIG. 13 show a view ofthe battery cover 554-side of battery 550, while FIG. 14 shows a view ofthe back plate 562-side of battery 550.

FIG. 15 illustrates an exploded view of an example of a housing of abattery 1500 into which the heat-shielding or blocking, heat-dissipatingand/or heat signature-reducing material is provided as a coating orlayer. The battery 1500 is an example of equipment that may be used bymilitary personnel. The battery 1500 is but one example of using theheat-shielding or blocking, heat-dissipating and/or heatsignature-reducing layer 120 for dissipating heat from and/or reducingthe heat signature of an article.

The battery 1500 includes a lid 1502 and a base 1504. The base 1504 hasa mounting plaque 1510 for mounting a latch on the base. The base 1504has a recessed hole 1508 for a connector on both sides of the base 1504.The lid 1502 includes holes 1512 to attach the lid to the base 1504. Thebase 1504 includes holes 1514 to attach the lid to the base of thehousing. Screws (not shown) are placed through holes 1512 and 1514 toattach the lid to the base. The lid 1502 includes a hole 1516 formounting a connector.

In one embodiment, the battery housing or base 1504 with sides dependingupwards therefrom is a unitary and integrally formed piece of plasticformed via injection molding. Advantageously, when the heat-shielding orblocking, heat-dissipating and/or heat signature-reducing material isutilized in conjunction with the base, the base can be manufactured frommuch thinner plastic than in prior art battery housings because theheat-shielding or blocking, heat-dissipating and/or heatsignature-reducing material effectively blocks, shields from, anddissipates heat. In contrast, prior art plastic battery housings requirethicker plastic to provide heat blocking, shielding, and dissipation.When used in conjunction with the heat-shielding or blocking,heat-dissipating and/or heat signature-reducing material, the thinplastic material requirement of the present invention provides for costsavings over the prior art. In fact, some embodiments of the housing ofthe present invention use materials and types of materials whichtraditionally have been disfavored because of the heat generated frombatteries. Such materials include by way of example not limitation,aluminum, titanium, nickel, magnesium, microlattice metals, compositemetal foams, and combinations thereof. Notably, many of these materialswere previously disfavored for the base because of the heat transfer anddissipation from the batteries. Materials which provide other advantagessuch as bullet resistance, such as composite metal foams, are also usedfor the base in one embodiment of the present invention.

The battery housing or base 1504 for removably holding at least onebattery is coated with a paint 1506 for reducing electromagneticinterference. In a preferred embodiment, the paint 1506 includes copper.Although the base 1504 of the at least one battery 1500 is coated withthe paint 1506, which functionally protects the bottom and sides of theat least one battery from external heat, the top of the battery isexposed to external heat when attached to heat generating equipment(e.g., radio). Since external heat can damage the battery and/or causeit to overheat, the heat-shielding or blocking, heat-dissipating and/orheat signature-reducing material layer or coating is functionallyconstructed and configured within the interior of the housing or base toprotect the removable batteries disposed therein. In this particularexample, the radio generates a significant heat profile and theheat-shielding material is operable to block that external heatemanating from the radio. The material is further functional todissipate heat generated by the at least one battery during operation ofthe radio, which draws power from the at least one battery, and reducesthe heat signature of the at least one battery disposed within thehousing or base.

In another example of embodiments of the present invention, theheat-shielding or blocking, heat-dissipating and/or heatsignature-reducing material completely covers the interior of a housinghaving a plurality of battery cells removably disposed therein. Otherexamples include a heat-shielding or blocking, heat-dissipating and/orheat signature-reducing material layer having anti-static, anti-radiofrequency (RF), anti-electromagnetic interference (EMI), anti-tarnish,and/or anti-corrosion materials and properties that effectively protectbattery-operated devices and/or the batteries that power them fromdamage or diminished operation.

The battery housing or base 1504 includes a plurality of sealed batterycells or individually contained battery cells, i.e. batteries with theirown casings, removably disposed therein. In a preferred embodiment, thebattery cells are electrochemical battery cells, and more preferably,include lithium ion rechargeable batteries. In one embodiment thebatteries are 18650 cylindrical cells. The plurality of battery cellsmay be constructed and configured in parallel, series, or a combination.Preferably, the plurality of electrochemical battery cells are removablydisposed within the base or battery housing or container. For example,the plurality of battery cells can be replaced if they no longer hold asufficient charge.

FIG. 16 illustrates a view of an example of a battery base 1504. Thebase 1504 is shown with a latch 1520. The latch 1514 is operable toattach the battery 1500 to a military radio (e.g., AN/PRC-117G) with acorresponding catch. A dust cap 1518 is attached to the battery base1504 via a lanyard 1516 attached to the mounting plaque. The length ofthe lanyard 1516 is such that no part of the dust cap 1512 is capable ofmoving underneath the battery 1500. Batteries often have the dust capattached to the housing via a dress nut, which allows the dust cap tomove underneath the battery. When the dust cap is underneath thebattery, the battery (and any equipment attached to the battery) maybecome unstable and tip over. If the dust cap is underneath the battery,it may lead to the dust cap being torn from the housing. The batterywould no longer be protected from dust and other environmentalcontaminants.

FIG. 17 illustrates another view of an example of a battery base 1504.In a preferred embodiment, the recessed hole 1508 includes a flat side1530 for installing a connector with a keyway. A right angle cable isused to connect the battery to external power consuming devices and/orexternal power sources. The keyway ensures that the right angle cabledoes not interfere with latches used to attach the battery to the radio.The keyway in FIG. 17 forces the cable to a 30.0° angle. Other anglesare compatible with the present invention.

FIGS. 18A-D illustrate various other views of the lid.

FIGS. 19A-F illustrate various other views of the base.

FIG. 20 illustrates a view of a BA-5590 female connector. In a preferredembodiment, the BA-5590 female connector is installed in the hole 1516of the lid.

FIG. 21 illustrates a block diagram of a portable power case into whichthe heat dissipating and/or heat signature-reducing material isinstalled. The portable power case 2100 is an example of equipment thatmay be used by military personnel. The portable power case 2100 is butone example of using the heat-shielding or blocking, heat-dissipatingand/or heat signature-reducing layer 120 for dissipating heat fromand/or reducing the heat signature of an article.

The portable power case 2100 has four access ports 2120A-2120D and twoUSB ports 2122A-2122B. The portable power case 2100 is operable toconnect to an amplifier 2104 through an access port (e.g., 2120A). Theamplifier 2104 connects to a radio 2102. The portable power case 2100 isoperable to be charged using a solar panel 2106 when connected to anaccess port (e.g., 2120B). The portable power case 2100 is operable tocharge a wearable battery 2108.

The portable power case 2100 and wearable battery 2108 are connectedthrough a DC-DC converter cable 2110 that is in contact with an accessport (e.g., 2120C). The portable power case 2100 is operable to becharged using a vehicle battery 2112. The vehicle battery 2112 isoperable to charge the portable power case 2100 for a brief period afterthe ignition of the vehicle is turned off. The system includes a batteryprotector 2114 connected to an access port (e.g., 2120D) to prevent thevehicle battery from being drained. The battery protector 2114 isconnected to the access port 2120D through a DC-DC converter cable 2116.The USB ports 2122A-2122B are operable to charge electronic devices,including, but not limited to, a mobile phone 2130 and/or a tablet 2132.

In a preferred embodiment, the amplifier is a 50 W wideband vehicularamplifier adapter (RF-7800UL-V150 by Harris Corporation) or a poweramplifier for the Falcon III VHF handheld radio (RF-7800V-V50x by HarrisCorporation). In a preferred embodiment, the radio is a PRC-117G.Alternative radios and/or amplifiers are compatible with the presentinvention.

FIG. 22 illustrates a block diagram showing the inside of one embodimentof the portable power case 2100. The portable power case 2100 iscomprised of two batteries 2202A-2202B and three batteries 2204A-2204C.In a preferred embodiment, the batteries 2202A-2202B are 29.4V lithiumion rechargeable batteries in a housing for mating with a PRC-117Gradio. In a preferred embodiment, the batteries 2204A-2204C are 29.4Vlithium ion rechargeable batteries in a housing for mating with aPRC-117F radio. Alternative voltages, housings, and/or number ofbatteries are compatible with the present invention. The batteries2202A-2202B and 2204A-2204C are connected to a PCB 2206. In a preferredembodiment, the batteries 2202A-2202B and 2204A-2204C include aheat-dissipating layer between the lid and the plurality ofelectrochemical battery cells.

FIG. 23 illustrates a block diagram of the connections to the PCB. ThePCB 2206 has four inputs. Batteries 2202A and 2202B are in parallel witheach other and connected to the PCB at INPUT 1. Battery 2204A isconnected to the PCB at INPUT 2. Battery 2204B is connected to the PCBat INPUT 3. Battery 2204C is connected to the PCB at INPUT 4. The PCB2206 has five outputs. OUTPUT 1 powers access port 2120A, OUTPUT 2powers access port 2120B, OUTPUT 3 powers access port 2120C, OUTPUT 4powers access port 2120D, and OUTPUT USB powers USB ports 2122A and2122B.

In a preferred embodiment, the PCB uses ferrite beads to provide EMIshielding. The PCB also uses capacitors to protect the batteries.

The portable power case is enclosed in a hard case (e.g., Pelican 1500)in a preferred embodiment. The hard case is comprised of polypropylenein one embodiment. FIG. 24 illustrates a view of the exterior of theportable power case. The case includes a top portion 2602 and a bottomportion 2604. A base for mounting at least one amplifier and at leastone radio 2606 is attached to the top portion 2602 through shockabsorbing cylinders 2608. The case includes latches 2610 for securingthe contents of the case, a pressure purge valve 2612, and a handle2614. The latches include rescue tape in a preferred embodiment toprevent the latches from rattling. A cap 2616 is provided to protect theUSB ports. A base for securing the portable power case to a vehicle 2620is attached to the bottom portion 2604 through shock absorbing cylinders2618.

In a preferred embodiment, the base for mounting at least one amplifierand at least one radio 2606, the shock absorbing cylinders 2618, and thebase for securing the portable power case to a vehicle 2620 arecomprised of a shock mount interface assembly (e.g., Harris12050-3050-01). Alternative mounts are compatible with the presentinvention.

FIG. 25 illustrates a view of the case with the cap (not shown) removedto show the USB ports. USB ports 2122A and 2122B are accessible on thefront of the case.

The hard case is lined with foam in one embodiment. Additionally oralternatively, the case is lined with a material that is resistant toheat and/or electromagnetic interference. FIG. 26 shows one example ofthe portable power case 2100 lined with material resistant to heat 120.The amplifier and radio give off a significant amount of heat. The heatresistant material prevents heat transfer from the amplifier and radioto the batteries. If a lithium ion battery overheats, it reducesperformance of the battery, reduces the life span of the battery, andmay result in a fire.

Additionally, the heat resistant material may also beanti-electromagnetic interference material. The anti-electromagneticinterference material lining creates a Faraday cage and preventsdisruption by electromagnetic radiation. In an alternative embodiment,the case may be coated with an electromagnetic interference and/or radiofrequency interference shielding paint including copper, silver, nickel,and/or graphite.

The portable power case provides for modularity that allows the user todisassemble and selectively remove the batteries installed within theportable power case housing that is lined with the heat-shielding orblocking, heat-dissipating and/or heat signature-reducing layer in apreferred embodiment. The modularity allows the user to comply withSurvival, Evasion, Resistance, and Escape (SERE) training. In case ofattack, each of the batteries can be used to power the at least oneradio and/or the at least one amplifier, as well as other gear.

The access ports are shown in FIG. 27A. The access ports are preferablystaggered vertically and horizontally to allow for easy access to theports. As shown in FIG. 27B, the preferred embodiment includes a keyway(shown as a flat portion of the connector) to ensure correct orientationof cables. In a preferred embodiment, the cables connected to the accessports located on the top row orient downwards and the cables connectedto the access ports located on the bottom row orient upwards.Alternatively, the cables connected to the access ports located on thetop row orient downwards and the cables connected to the access portslocated on the bottom row orient downwards. A gasket 2702 is providedaround each of the access ports to seal the interior of the case fromthe external environment.

The four access ports are on the left side of the case in a preferredembodiment. FIG. 28 illustrates a block diagram of a portable power casein an ATV with three passengers. The ATV 2800 has a steering wheel 2802and a seat for a driver 2804. A seat for a first passenger 2806 is tothe right of the driver. The first passenger is responsible formaintaining the security of the right side of the ATV. A seat for asecond passenger 2808 is behind the driver. The second passenger isresponsible for maintaining the security of the left side of the ATV.The location of the first passenger and the second passenger allow for360 degree visual coverage of the landscape surrounding the ATV. Theportable power case 2100 is located to the right of the secondpassenger. Placing the access ports on the left side of the caseprevents the second passenger and/or gear from knocking the cablesconnected to the case loose from the access ports. The trunk 2810 isavailable for storing additional gear.

FIG. 29 illustrates a block diagram of a portable power case in an ATVwith four passengers. The ATV 2800 has a steering wheel 2802 and a seatfor a driver 2804. A seat for a first passenger 2806 is to the right ofthe driver. A seat for a second passenger 2808 is behind the driver. Thesecond passenger is responsible for maintaining the security of the leftside of the ATV. A seat for a third passenger 2812 is to the right ofthe seat for the third passenger 2808. The portable power case 2100 isplaced in the trunk 2810.

The portable power case has two USB ports for charging electronicdevices (e.g., mobile phone, tablet, smartphone, camera, globalpositioning system devices (GPS), thermal imaging devices, weaponoptics, watches, satellite phones, defense advanced GPS receivers) in apreferred embodiment. The USB ports are preferably located on the frontside of the case. Alternatively, the USB ports are located on the leftor right side of the case.

The system allows the portable power case to charge using the vehiclebattery after the ignition is turned off. The system includes a batteryprotector to prevent users from being stranded due to a drained vehiclebattery.

FIG. 30 illustrates a block diagram of the battery protector. Thebattery protector includes INPUT from the vehicle battery 2112 andOUTPUT to the DC-DC converter 2116. A green LED 3002 and a red LED 3004provide visual information regarding the current charge status. Thebattery protector includes a rotary switch 3008 to select a desired timeor voltage setting.

In one embodiment, the battery protector is a timer set to a time wherethe load will not drain the battery (e.g., 2 minutes, 15 minutes, 30minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 8 hours, or 12hours). Additionally or alternatively, the battery protector is a lowvoltage disconnect (LVD) that automatically disconnects the load whenthe vehicle battery voltage falls below a set DC voltage (e.g., 10.6V,10.8V, 11.0V, 11.2V, 11.4V, 11.6V, 11.8V, 12.0V, 12.1V, or 12.2V). Inone embodiment, the battery protector automatically reconnects the loadwhen the battery voltage returns to a normal value (e.g., above the setDC voltage) after charging.

The battery protector has over voltage protection that automaticallydisconnects the load when the battery protector detects a voltage higherthan a set DC voltage (e.g., above 16V) in a preferred embodiment. Inone embodiment, the battery protector automatically reconnects the loadwhen the detected voltage falls below the set DC voltage (e.g., below16V).

The battery protector includes an emergency override switch 3006 in oneembodiment. This allows the load to charge using the vehicle battery foran additional period of time (e.g., 15 minutes) in an emergency byoverriding a timed out timer.

In a preferred embodiment, the battery protector includes a visualindicator (e.g., LED lights) to indicate a current status. In oneembodiment, the battery protector has a green LED light to indicate thatthe engine is running and the load is charging; a flashing green LEDlight to indicate that the vehicle engine is off, the timer has started,and the load is charging; a flashing red LED light to indicate that thetimer has expired and the load is no longer charging; a slow flashingred LED light to indicate that the vehicle battery voltage is below theset DC voltage and the load is no longer charging; and a solid red lightto indicate an overvoltage condition. The battery protector ispreferably waterproof

The system also allows the portable power case to charge using at leastone alternating current (AC) adapter. All four access ports can be usedto charge the portable power case. In one embodiment, the power can becharged in 16 hours using one AC adapter, 8 hours using two AC adapters,and 4 hours using four AC adapters.

In a preferred embodiment, the at least one AC adapter accepts a100-240VAC input and has a DC output of 17.4V. In one embodiment, the atleast one AC adapter has an indicator for the charge state (e.g.,red/orange indicates charging and green indicates charged).

In a preferred embodiment, the solar panel comprises a combinationsignal marker panel and solar panel, such as that disclosed in USPublication No. 20150200318 and U.S. application Ser. No. 15/390,802,each of which is incorporated by reference in its entirety.

In a preferred embodiment, the solar cells are comprised of microsystemenabled photovoltaic (MEPV) material, such as that disclosed in U.S.Pat. Nos. 8,736,108, 9,029,681, 9,093,586, 9,143,053, 9,141,143,9,496,448, 9,508,881, 9,531,322, 9,548,411, 9,559,219 and US PublicationNos. 20150114444 and 20150114451, each of which is incorporated byreference in its entirety. The signal marker panel is fluorescent orange(or “international orange”) on a first side and cerise on a second side.

The system can be also charged using non-rechargeable batteries (e.g.,BA-5590) and NATO generators.

The wearable battery 2108 is preferably the battery shown in FIG. 12B,wherein the battery is lined with a first layer of the heat-shielding orblocking, heat-dissipating and/or heat signature-reducing material and asecond layer of the heat-shielding or blocking, heat-dissipating and/orheat signature-reducing material, e.g., in a layer or lining, or coatingapplication.

The above-mentioned examples are provided to serve the purpose ofclarifying the aspects of the invention, and it will be apparent to oneskilled in the art that they do not serve to limit the scope of theinvention. By way of example, the keyway may force the cable at an angleother than 30.0°. Voltages of batteries may be different.

The above-mentioned examples are just some of the many configurationsthat the mentioned components can take on. All modifications andimprovements have been deleted herein for the sake of conciseness andreadability but are properly within the scope of the present invention.

The invention claimed is:
 1. A battery housing unit comprising: a lid; abase; a plurality of electrochemical battery cells removably providedwithin the base; and a heat-shielding, heat-dissipating, and heatsignature-reducing layer functionally positioned between the lid and theplurality of electrochemical battery cells for blocking heat fromexternal objects, dissipating heat from the plurality of electrochemicalbattery cells, and reducing the heat signature from the plurality ofelectrochemical battery cells; wherein the base further includes: atleast one mounting plaque; a latch secured to a corresponding at leastone mounting plaque; at least one recessed hole; at least one connectorsecured in the at least one recessed hole; a dust cap to cover the atleast one connector; and a coating to protect the plurality ofelectrochemical battery cells from electromagnetic interference.
 2. Thebattery housing unit of claim 1, wherein the coating comprises copper.3. The battery housing unit of claim 1, wherein the plurality ofelectrochemical battery cells is sized to mate with and power a radio.4. The battery housing unit of claim 1, wherein the lid has a connector.5. The battery housing unit of claim 4, wherein the connector is aBA-5590 female connector.
 6. The battery housing unit of claim 1,wherein the heat-shielding, heat-dissipating, and/or heatsignature-reducing layer is comprised of a polymer and copper.
 7. Abattery housing for reduced heat transfer comprising: a lid removablysecurely connected with a base having sides depending upward therefromconstructed and configured for receiving a plurality of battery cellsremovably provided within the base; and a heat-shielding,heat-dissipating, and heat signature-reducing material layer affixed tothe interior surface of the lid that is functional for blocking heatfrom external objects, dissipating heat from the plurality of batterycells, and reducing the heat signature from the plurality of batterycells; wherein the base further includes a coating comprising at leastone heat-shielding, heat dissipating, and heat signature-reducingmaterial that is functional for blocking heat from external objects,dissipating heat from the plurality of battery cells, and reducing theheat signature from the plurality of battery cells.
 8. A battery housingfor reduced heat transfer comprising a unitary and integrally formedplastic injection-molded base having sides depending upward therefromconstructed and configured for receiving a plurality of battery cellsremovably provided within the base; and a heat-shielding,heat-dissipating, and heat signature-reducing material layer affixed tothe interior surface of the lid that is functional for blocking heatfrom external objects, dissipating heat from the plurality of batterycells, and reducing the heat signature from the plurality of batterycells; wherein the base further includes a coating comprising at leastone heat-shielding, heat dissipating, and heat signature-reducingmaterial that is functional for blocking heat from external objects,dissipating heat from the plurality of battery cells, and reducing theheat signature from the plurality of battery cells.